hydronic water heat install guide - affordable home inspections

Hydronic Fan CoilManual of Installation, Operation andMaintenance

ALL TECHNICAL AND WARRANTY QUESTIONSSHOULD BE DIRECTED TO THE LOCAL DEALER FROMWHOM THE AIR HANDLER WAS PURCHASED. IF YOUARE UNSUCCESSFUL, PLEASE WRITE TO APOLLOHYDROHEAT AND COOLING AT THE ADDRESSLISTED BELOW.

Fill in the rating plate informationhere:MODEL NO. ____________________________________SERIAL NO. _____________________________________INSTALLATION DATE ____________________________

Month Day Year

0002916570-0

Fill in the installation informationhere:Installer _________________________________________Street Address ___________________________________City/State/Zip ____________________________________Phone # _________________________________________

Distributor_______________________________________Street Address ____________________________________City/State/Zip ____________________________________Phone # _________________________________________

Repair PartsFOR SERVICE OR REPAIR PARTS CONTACT:

First: The Installing Contractor

Second: The Local Distributor

Third: Apollo HydroHeat and Cooling500 Lindahl ParkwayAshland City, TN 37015

This manual contains instructions for the installation,operation and maintenance of the Hydronic Fan Coil.Some models are equipped with heating only coils. Readit carefully before using the air handler. Then keep ithandy for quick future reference by inserting it in theplastic envelope provided on the appliance.

Rating PlateA rating plate identifying the air handler will be foundinside the front access panel. A rating plate identifying thewater heater will be found above or to the left of the gascontrol valve. When referring to the air handler and/orwater heater, always have the information listed on therating plate readily available.

ConsumerResponsibilitiesPlease take the time to read not only this manual but alsothe warranty sheet enclosed. Warranty of parts and the airhandler will depend on the proper installation,maintenance and operation of the air handler.Furthermore, the warranty shall be void if the design orstructure of the air handler is, or is attempted to be,modified or altered in any way, including, but not limitedto, by attaching non-Company approved appliances orequipment.

The manufacturer of this air handler will not be liable forany damages because of failure to comply with theinstallation and operating instructions outlined on thefollowing pages. Use them as a guide to check thepropriety of the air handler installation.

You will need to maintain the air handler and waterheater as outlined in this manual.

Equipment in this carton was inspected and verified to bein good condition at the time it left the factory. Whenreceived, a visual inspection of the equipment should bemade and any damage noted on the delivery receipt. Adamage claim should then be filed immediately with thecarrier.

VERTICAL AIRFLOW

HORIZONTAL AIRFLOW

How the System WorksThis section will answer many of the most often askedquestions about the system.

How does it work?

The heating system uses a gas water heater to furnish heatto the space of a residence, as well as its domestic hotwater. A simple recirculating loop of hot water is tapped offnear the top of the heater and is circulated through a finnedtube heat exchanger in an air handler or duct coil thatfurnishes warmed air to the space. The cooled water (140°cooled to about 120°) is then returned to the water heater,near the bottom of the tank. Each air handler includes acirculating pump and controls, factory piped and wired.

The water heater may include side tappings to provide therecirculating loop connections. When a conventionalheater is used, special fittings including check valves areused at the hot and cold water connections.

The control of the heating system is very simple. Aconventional heating or heating/cooling thermostat is used.On a call for heat, the hot water circulator is energizedthrough a relay, as is the blower motor. Hot waterimmediately begins circulating through the heat exchanger,and heats the air. Typical leaving air temperatures are 95°–105°. When the thermostat is satisfied, the pump andblower both stop.

How is a Hydro Heat System sized?

Proper sizing of the water heater is essential, and beginswith the ACCA Manual J design heat loss of the structure tobe heated. The heating capacity of the air handler of coilselected must be equal to or larger than the design heatloss. Then, the water heater selected must have a heatoutput equal to or greater than the coil or air handlerheating capacity.

Does a Hydro Heat System require a larger tank size?

In general, it does not require a larger tank size to furnishspace heat as well as domestic water. When propercalculation has been made to determine the BTUH inputrequired, and the heater has been selected on that basis,the tank size must be no smaller than 40 gallons, andshould be at least that normally used for the expectedoccupancy of the home.

105°-120° WATERAPOLLO AIRHANDLER

COOLING COIL

HOT WATERTO HOUSE

COLD WATERIN

GASWATER HEATER

120°-140°WATER

PUMPHEAT

EXCHANGER

BLOWER CONDENSATEDRAINPAN

105°-120° WATER

AIR HANDLER

COOLING COIL

HOT WATERTO HOUSE

COLD WATERIN

GASWATER HEATER

120°-140° WATER

PUMP

HEATEXCHANGER

BLOWER

CONDENSATEDRAIN PAN

2

Table of ContentsRating Plate................................................................................................................................................1

Consumer Responsibilities..........................................................................................1

Repair Parts ...............................................................................................................................................1

How the System Works......................................................................................................2

Safety......................................................................................................................................................................4

Preparing for the New Installation.......................................................4-11Location.............................................................................................................................................................................4Clearance to Combustible Materials ...................................................................................................................................4Typical Installations ...........................................................................................................................................................5 Installation Notes ...............................................................................................................................................................6Conventional Water Heater Supplying a Single Air Handling Unit....................................................................................6Circulating Loop Water Heater Supplying a Single Air Handling Unit...............................................................................6

Water Piping ......................................................................................................................................................................7Water Pressure ...................................................................................................................................................................7Discharge Ducting .............................................................................................................................................................7Return Ducting...................................................................................................................................................................7Optional Air Filter ..............................................................................................................................................................8Condensate Drain ..............................................................................................................................................................8Low Voltage Wiring ...........................................................................................................................................................8Line Voltage Wiring ...........................................................................................................................................................8Wiring Diagrams................................................................................................................................................................8Low Temperature Protection Switch...................................................................................................................................9Refrigerant Piping...............................................................................................................................................................9Charging by Superheat .....................................................................................................................................................10System Start Up Procedure ...............................................................................................................................................11Water Heater Temperature Adjustment ............................................................................................................................11System Shutdown.............................................................................................................................................................11

Setting Equipment.................................................................................................................12-25RFC Series ...................................................................................................................................................................12-13HH Series .........................................................................................................................................................................14VB Series ..........................................................................................................................................................................15HB Series ....................................................................................................................................................................16-17W Series......................................................................................................................................................................18-19S,M&L Heating Only Models............................................................................................................................................20S,M&L with Evaporator Coil ........................................................................................................................................21-23H Series.......................................................................................................................................................................24-25

Troubleshooting.........................................................................................................................26-27Do’s and Don’ts ...............................................................................................................................................................26Air Handler Service Checklist ...........................................................................................................................................27

Product Warranty...................................................................................................................28-29

3

SafetyWARNING

HOTTER WATER CAN SCALD: Water heaters areintended to produce hot water. Water heated to atemperature which will satisfy space heating, clotheswashing, dish washing, and other sanitizing needs canscald and permanently injure you upon contact. Somepeople are more likely to be permanently injured byhot water than others. These include the elderly,children, the infirm, or physically/mentallyhandicapped. If anyone using hot water in your homefits into one of these groups or if there is a local codeor state law requiring a certain temperature water atthe hot water tap, then you must take specialprecautions. In addition to using the lowest possibletemperature setting that satisfies your hot water needs,a means such as a mixing valve, shall be used at the hotwater taps used by these people or at the water heater.Mixing valves are available at plumbing supply orhardware stores. Follow manufacturers instructions forinstallation of the valves. Before changing the factorysetting of the thermostat read the “TemperatureRegulation” section in this manual.

WARNINGDo not use this appliance if any part has been underwater. Immediately call a qualified service technicianto inspect the appliance and to replace any part of thecontrol system which has been under water.

Preparing for the New InstallationNote: Information in this section is generic. Refer to “Setting Equipment” section of this manual for specific models.

LocationThere may be up to 70′ of separation between the airhandler and water heater. The location selected for thewater heater should be as close to the stack or chimneyas practical, and as centralized with the piping system forthe air handler as possible. They (air handler/waterheater) should be located in an area protected from theelements.

In installations in areas that may experience freezingtemperatures, care should be taken to protect equipmentfrom freezing, and dwelling from water damage, shouldfreezing occur. See “Low Temperature Protection Switch”on page 9.

NOTE: The locations selected should provide adequateclearances for servicing and proper operation of the airhandler.

Clearance to CombustibleMaterialsThe air handler can be operated with 0″ of clearance tocombustible materials from any side, front or back.Discharge clearance is also 0″.

NOTE: For water heater clearances see instructionmanual that was included with the water heater.

NOTE: When these units are installed without return airducts, applicable installation codes may restrict theirinstallation to a single story residence.

CAUTIONThis hydronic air handler as all hydronic air handlerswill eventually leak. Do not install without adequatedrainage provisions where water flow will causedamage.

4

Preparing for the New InstallationTypical InstallationsNote: Typical Installation drawings are generic. Air handler and water heater styles vary by model. Refer to “SettingEquipment” of this Manual for specific models.Specifications subject to change without notice. Installation of this product must comply with prevailing building, safety andN.E.C. codes and should be in accordance with manufacturer’s instructions.

Water Heaters used for space heating must be listed and labeled as “suitable for (potable) water heating and space heating”.

Water heaters used for space heating must also be used for domestic (potable) water heating.

CHIMNEY OR GAS VENT

CHECK VALVE(if not installedin air handler)

DISCHARGE LINE(Do not cap or plug)

TEMPEREDWATEROUTLET

TO SUITABLE DRAIN

CHECK VALVE (if not installed in air handler)

COLDWATERINLET

SHUT-OFFVALVE

*MIXINGVALVE

6″ AIR GAP

HOT TO AIR HANDLER

CHIMNEY OR

GAS VENT

SHUT-OFFVALVE

DISCHARGE LINE(Do not cap or plug)

TEMPEREDWATEROUTLET

TO SUITABLE DRAIN

GAS SUPPLY

COLD WATER INLETHOT WATEROUTLET

SHUT-OFFVALVE

*MIXINGVALVE

CHECK VALVE(if not installedin air handler)

DRIP LEG(Sediment Trap)

SHUT-OFFVALVE

GAS SUPPLY

DRIP LEG(Sediment Trap)

6″ AIR GAP

RETURN FROM AIR HANDLER

5

PURGE VALVE(if not installed in air handler)

PURGE VALVE(if not installed in air handler)

WARNINGWhen the system requires water at temperatures higherthan required for other uses, the hot water system mayrequire a means such as a mixing valve to be installed totemper the water at certain points of use. Some peopleare more likely to be permanently injured by hot waterthan others; these include the elderly, children, theinfirm, or the physically/mentally handicapped. Beforeimmersing yourself or anyone else in hot water, be sureto check the water temperature. WARNING: HOTTERWATER INCREASES THE RISK OF SCALD INJURY. (Alsosee “Temperature Regulation” section in water heatermanual) Mixing valves are available at plumbing supplyor hardware stores. Follow manufacturers instructionsfor installation of these valves.

Note: If the Air Handler is equipped with an internalcheck valve, do not install a check valve in the supplyline to the air handler.

SECONDARYDRAIN

PRIMARYDRAIN

COLD OUTLET

THERMOSTAT

HOT INLET

AIR HANDLERUNIT

HOT WATER INLET

COLD WATER OUTLET

PRIMARY DRAIN

DRAIN PAN

AIRHANDLER

UNIT

THERMOSTAT

SECONDARYDRAIN

DRAIN PAN

SUPPLY

ELECTRICALCONNECTIONS

AIR HANDLERw/HEATING COIL

WATERCONNECTIONS

PIPED TO AN ADEQUATE DRAIN

PLENUM

PRIMARY DRAIN

DRAIN PAN

REFRIGERATIONCONNECTIONS

SECONDARYDRAIN

FILTERGRILL

RETURN

Install the depneumatic fitting into the hot outletfitting of the water heater.Out of the top of the depneumatic fitting run a 3⁄4″pipe of copper or approved plastic to the inlet fittingon the air handler. The tapping in the side of the depneumatic fitting is the domestic hot supply andshould be piped to the hot supply line.The cold side piping should be done as shown inthe diagram.

4. Heating Unit Supply Connection labeled–“Hot InletSupply from Water Heater”.

5. Heating Unit Return Connection labeled–“ColdOutlet Return to Water Heater”.

6. Because inlet and outlet positions are different oneach model, refer to labeling on the cabinet.

7.

Circulating Loop Water Heater Supplying aSingle Air Handling Unit

1. Total piping footage should not exceed 140 feet. 2. All piping should be 3⁄4″ copper or approved plastic

(Note: Acetal plastic fittings should not be used inrecirculating hot water systems. Use only brass orcopper fittings.)

3. Hot supply tapping labeled–“Hot (Outlet)Recirculating Loop Connection.”

4. Cold return tapping labeled–“Cold (Return)Recirculating Loop Connection”.

5. Heating unit supply connection labeled–“HotInlet–Supply From Water Heater.”

6. Heating unit return connection labeled–“ColdOutlet–Return to Water Heater.”

7. Because inlet and outlet positions are different oneach model, refer to labeling on back of cabinet.

8.

➂

➄ ➅

➃

Installation NotesNote: Installation notes are generic. Air handler andwater heater styles vary by model.

Conventional Water Heater Supplying a SingleAir Handling Unit

1. Total piping footage should not exceed 140 feet.2. All piping should be 3⁄4″ copper or approved plastic.

NOTE: Acetal plastic fittings should not be used inrecirculating hot water systems. Use only brass orcopper fittings.

3. A depneumatic fitting is not supplied. This devicemust be installed when there is greater than an 8foot change in elevation between the top of the airhandler and top of the water heater.

6

➇

➂➆

SUPPLY



WATERCONNECTIONS


PLENUM

PRIMARY DRAIN

DRAIN PAN


SECONDARYDRAIN

FILTERGRILL

RETURN

NOTE: Water heaters that have an anode rod oranother fitting in the hot outlet cannot be used.The depneumatic fitting will not work on these.NOTE: The depneumatic fitting with supply lineand return line check valves is available as a kit(Accessory 9001309).

WARNINGWhen the system requires water at temperatureshigher than required for other uses, the hot watersystem may require that a means such as a mixingvalve be installed to temper the water at certainpoints of use.

WARNINGWhen the system requires water at temperatureshigher than required for other uses, the hot watersystem may require that a means such as a mixingvalve be installed to temper the water at certainpoints of use.

Preparing for the New Installation (cont’d)

➆

HOT SUPPLY TO AIR HANDLER

COLD RETURN FROM AIR HANDLER

DEPNEUMATIC FITTING KIT (part #9001309)

A depneumatic fitting should be used if this unit isinstalled with any water heater other than a sideconnection circulating loop water heater. They must beinstalled in the water heater as shown.

HOT WATER TO HYDRO HEAT UNIT

WATER FROM HYDRO HEAT UNIT

HOT CHECK(IF NOT IN AIR

HANDLER)

VOLUME PURGEVALVE (FIELDSUPPLIED – MAYBE IN AIRHANDLER)

COLDWATER IN

DEPNEUMATICDIP TUBE

HOT WATER TO HOUSE

➃ ➄

Pipes and fittings should be installed in compliance withthe installation drawing and all applicable local codes.Have the installer show you where the water shut offvalve for the water heater is installed so that you knowwhere and how to shut the water off. It is recommendedthat such a valve be located in close proximity to thewater heater. See installation drawings on page 5.To insure complete filling of the system, follow “SystemStart Up Procedure” section on page 10.

Water PipingThis air handler is intended for use with pressurizedpotable hot water sources with the rated maximumentering water temperature on the air handling unit. Forsystems using oil or gas-fired domestic water heaters as ahot water source, pipe as shown in the diagram on page5. The system should be installed only with new pipingthat is suitable for potable water, such as copper or hotpolybutylene. Do not use with PVC piping. All pipingshould be done in 3⁄4″ with a maximum total pipingfootage of 140 feet. The unit has 1⁄2″ I.D. copper waterconnections, therefore, a 3⁄4″x1⁄2″ adapter is required. Thecabinet finish should be shielded from the torch flameduring soldering. Piping run through unconditioned areasshould be insulated to prevent freezing and minimizeheat loss.

7

CAUTIONAfter system has been checked, do not allow it to bedrained or shut off if there is a possibility of freezing.See System Shutdown section.

WARNINGWhen the system requires water at temperatures higherthan required for other uses, the hot water system mayrequire a means such as a mixing valve to be installed totemper the water at certain points of use. Some peopleare more likely to be permanently injured by hot waterthan others; these include the elderly, children, theinfirm, or the physically/mentally handicapped. Beforeimmersing yourself or anyone else in hot water, be sureto check the water temperature. WARNING: HOTTERWATER INCREASES THE RISK OF SCALD INJURY. (Alsosee “Temperature Regulation” section in water heatermanual) Mixing valves are available at plumbing supplyor hardware stores. Follow manufacturers instructionsfor installation of these valves.

CAUTIONOperating an empty or partially filled system will resultin damage.

WARNINGToxic chemicals such as used for treatment of boilersor non-potable water heating appliances shall never beintroduced into a potable water space heating system.


If a system (air handler/water heater) is installed in aclosed and/or high pressure water system; such as onehaving a back flow preventer, check valve or water meterwith check valve in the cold water supply line, meansshall be provided to control thermal expansion. Contactthe water supplier or local plumbing contractor on howto control this situation.

Water PressureThe water supply system incorporates the air handler andwater heater and conditions created in the water supplysystem and effected by the water heater also involve theair handler.

Water supply systems may, because of high line pressurefrequent cut-offs, the effects of water hammer and others,have installed devices such as pressure reducing valves,check valves, back flow preventers, etc...to control thesetypes of problems. When these devices are not equippedwith an internal by-pass, and no other measures aretaken, they (the devices) cause the water system to beclosed. As water is heated, it expands (thermal expansion)and closed systems do not allow for the expansion ofheated water.

The water within the water heater tank expands as it isheated and increases the pressure of the water system. Ifthe relieving point to the water heater’s temperature-pressure relief valve is reached, it (the T&P valve) willrelieve the excess pressure. This is an unacceptablecondition and must be corrected.

It is recommended that any devices installed which couldcreate a closed system, have a by-pass and/or the systemhave an expansion tank to relieve the pressure built bythermal expansion in the water system. Contact the localwater supplier and/or plumbing contractor for assistancein controlling these situations.

Discharge DuctingThis unit has its blower discharging directly into thesupply duct system resulting in high velocities close to theend of the unit. To insure efficient air flow the supplyplenum attached to this unit should be a minimum ofthree feet long. Also outlet runs should tap into this ductas far from the end of the unit as possible. Avoid registerswithin line of sight of the blower outlet.

Return DuctingAir velocity in return should be as low as practical. 400feet per minute or less is good design. Filters should notexceed 400 feet per minute air velocity.

Low Voltage Wiring(Except RFC Series, Refer to “Setting Equipment”section)Connections of the low voltage thermostat and condensercontrol are to be made to the low voltage harnessexposed on the outside of the cabinet. When splicingthese wires, the use of insulated butt splices instead ofwire nuts will yield a neater, more reliable connection.

Make low voltage connections to thermostats andcondensing units as shown in the wiring diagrams.Conventional heat/cool or heating only thermostats willwork satisfactorily.

Line Voltage WiringLine voltage wiring should be done in compliance withall national and local codes. The 7⁄8″ hole located in thedischarge end of the unit provides access to the linevoltage lead wires. Wire incoming power as described onthe schematic.

8

Optional Air FilterAir handlers may or may not be factory equipped with anair filter. Many times a filter will not be installed becausethe return grille has its own filter. In these cases a filterinstalled in the air handler is not recommended. Byreferring to the repair parts chart, the location can beestablished. Removing the access panel will gain accessto the filter. It should be checked periodically andreplaced if necessary. The filter is a standard item that canbe obtained locally.

Condensate DrainThe internal air handler drain pan is supplied to removenormal condensation. The primary stub is 3⁄4″ N.P.T. andthe secondary stub may be 5⁄8″ or 3⁄4″ N.P.T. Piping fromeach stub is to have a 11⁄2″ minimum trap and each be runis such a manner as to provided enough slope foradequate drainage to a visible area. Do not pipe these twofittings together into a common drain. When horizontalrun exceeds 15 feet, a vent tee may be necessary to gobetween the unit and the trap to insure proper drainage.The condensate drainage system should be tested bypouring water into the unit drain pan prior to operation ofthe unit.


SINGLE SPEED OPERATION

Br BROWN GY GRAY O ORANGE Y YELLOW Bl - MEDR - LOW

TACO PUMP

FIELD WIRINGFACTORY WIRING

FANRELAY

PUMPRELAY

TRANS

PRI

SEC

FANMOTOR

0591994-00

T-STAT

HEATVALVE

MAX 18 VA24 VOLTS TOFIELD SUPPLIEDHEAT VALVE

24 VOLTCONDENSERCONTROL

NOTE: USE THERMOSTAT WITHISOLATING CONTACTS TO PREVENT INTERCONNECTIONOF CLASS 2 CIRCUITS

SUPPLY CIRCUIT120/60/1BY N.E.C.

B

GN

WW

B

RBr

Br

BlO

WGN

GRUND-FOS PUMP

LOW TEMPERATUREPROTECTION MAKE ONTEMP. FALL 38°F

TWO SPEED OPERATION

Wiring Diagrams

9

INSTALLATION

Install the low temperature protection switch near thefront of the coil as shown in the illustration. Select alocation between tubes. Open a space in the fins byinserting a screwdriver and twisting. DO NOT DAMAGETUBES. Insert the sensor and pinch fins around it toassure secure installation. Wiring should be routed to thecontrol box in such a way as to prevent accidentalremoval of the sensor during any future servicing of theequipment.

Refrigerant PipingUnits equipped with evaporators will require liquid andinsulated suction piping sized in accordance with thecondensing unit manufacturer’s recommendations. Theevaporator coils are fitted with copper stubs to which therefrigerant line should be soldered. Use silver solder orother high temperature brazing alloy intended forrefrigeration work. The stubs are located close to the sideof the cabinet so it is a good idea to protect the cabinetinsulation from flame damage with a small piece of sheetmetal. Also, the manufacturer recommends that therefrigerant lines are filled with dry nitrogen beforesoldering. This will minimize the formation of ash insidethe lines that can clog the capillary strainer or orificemetering device.

Low Temperature ProtectionSwitchThis appliance is furnished with a field installed LowTemperature Protection Switch (LTP). The LTP is a switchintended to operate the circulating pump in the heatingsystem when internal temperatures approach freezing.The LTP will not function during a power outage.


WIRING

This switch is a Low Voltage device. It should be wired inparallel with the Red and Blue Low Voltage leads, asshown in wiring diagram included.

When retrofitting equipment with this control, replaceexisting wiring diagram with the diagram included withthis kit.

SUCTION SATURATEDPRESSURE SUCTION

PSIG TEMP. °F54.9 3057.5 3260.1 3462.8 3665.6 3868.5 4071.5 4274.5 4477.6 4680.8 4884.0 5087.4 5290.8 5494.3 5697.9 58101.6 60

PRESSURE TEMPERATURECHART — R22

CAUTIONIf during charging time, indoor W.B. changes more than2° or outdoor ambient more than 3°, check SuperheatTable for new superheat and charge to this superheat.

PROPER SUPERHEAT ASSURES PROPER SYSTEM CAPACITY AND EFFICIENCY.

10


Example of checking system chargeby SuperheatAssume condenser air inlet D.B. to be 90°F andevaporator air inlet W.B. to be 68°F. From the SuperheatTable we find the correct superheat for these conditionsto be 15 degrees.

The suction pressure at the time is 60 PSIG and suctionline temperature is 55 degrees. Using PressureTemperature chart we find that for a 60 PSIG suctionpressure – the evaporator saturation temperature will be34 degrees.

The difference between suction line temperature andsaturation temperature is the amount of superheat.

Suction line temp. 55°– Suction press. @ 60 PSIG 34° Saturation temp.= Superheat 21°

The 21° superheat is higher than the required 15°. Thesystem is undercharged. As we add refrigerant, thesuction pressure will rise causing saturation temperatureto rise. At the same time, suction vapor temperature willfall. In other words the two temperatures will come closertogether as refrigerant is added.

SUCTIONVAPOR TEMP.

SUCTION PRESS.CONDENSINGUNIT

Measuring Superheat1. Make sure evaporator coil has rated CFM of air flow.

2. Install accurate refrigerant pressure gauge to suctionservice valve gauge port or fitting at the condensing unit.

3. Attach an accurate thermometer to the bottom side ofsuction line as close to gauge port as possible. Makesure thermometer is in good thermal contact withsuction line. Insulate the thermostat and suction lineagainst effects of ambient air temperature.

4. With unit operating, measure condenser inlet air drybulb temperature and evaporator inlet air wet bulbtemperature.

5. Using the Superheat Table, find proper superheat at theintersection of these two temperatures.

6. Measure suction pressure. Using Pressure TemperatureChart, find evaporator saturated suction temperature forthis pressure.

7. Measure suction line temperature at condensing unit.

8. The difference between suction line temperature andsaturated temperature is the amount of superheat.

9. If superheat is too high – refrigerant must be added. Ifsuperheat is too low – refrigerant must be removed.

CONDENSER EVAPORATOR AIR INLET TEMP. – °F – W.B.AIR INLET

TEMP. – °F – D.B. 54 56 58 60 62 64 66 68 70 72 74 76

60 13 17 18 20 24 26 28 30

65 11 13 17 17 18 22 25 28 30

70 8 11 12 14 16 18 22 25 28 30

75 7 10 12 14 16 18 23 26 28 30

80 6 8 12 14 16 18 23 27 28 30

85 6 8 12 14 17 20 25 27 28

90 6 9 12 15 18 22 25 28

95 7 11 13 16 20 23 27

100 8 11 14 18 20 25

105 6 8 12 15 19 24

110 7 11 14 18 23

115 8 13 16 21

SUPERHEAT TABLE

CAUTIONWait at least 5 minutes after adding or removingrefrigerant from system before attempting to re-measuresuperheat.

Charging By SuperheatCharging by superheat is the most precise method of gettingthe optimum refrigerant charge in an air conditioningsystem. This method best matches the system’s ability toabsorb heat, with the available heat load on the evaporator.Superheat charging can be used on any air conditioningunit with cap tube or fixed orifice liquid control whencharging is done in ambient temperatures above 60°F.Superheat in this type of system will vary with change ofconditions of air over the condenser and evaporator. Theamount of superheat at the compressor must be adjusted tomeet these conditions.

System ShutdownFor short periods of time during freezing temperatures ifthe system is to be left unused, to prevent freezing of theair handler and piping, the system cannot be turned off.Leave the gas control valve at its lowest setting and theair handler’s thermostat left on heat setting. If the waterheater and air handler must be shut down for extendedperiods, a qualified service agent needs to be used toinsure the air handler and piping are drained of all water.

WARNINGThe water passing out of the drain valve may beextremely hot. To avoid being scalded, make sure allconnections are tight and that the water flow isdirected away from any person.

CAUTIONPeriodic draining and cleaning of sediment from thewater heater tank may be necessary.

System Start Up ProcedureNOTE: Heating system should not be switched on untilsystem filled and pumps vented.

1. Fill and pressurize the water heater and air handler.

2. The water heater should be started. At this time it willtake approximately 45 minutes for it to come up totemperature. Lighting instructions will be found on therating plate attached to the water heater.

3. Vent air from the water tank by opening a hot waterspigot.

4. Vent and flush the supply and return lines by opening theinstalled volume purge valve in the air handler or a fieldinstalled purge valve on the return line of the heatingloop. Run approximately 5 gallons of water at a highflow rate to purge.

Water Heater TemperatureAdjustmentThe water temperature dial of the water heater is set atthe lowest position during manufacture and must beturned to the desired setting by the user. The faceplate ofthe gas control has been labeled with a range oftemperature settings.

Due to the nature of the typical gas water heater thewater temperature in certain situations may vary up to30°F higher or lower at the point of use such as,bathtubs, showers, sinks, etc.

Common safety practices, American National Standards, andvarious state and local laws demand that warnings of scaldhazard from water temperatures in excess of 120°F be given tousers.

In dual use (water heating/space heating), higher temperaturesmay be necessary for the space heating requirement. In suchcases, the use of a tempering device such as a mixing valve isrecommended as indicated in the warning on page 5.

NOTE: For complete details concerning temperatureadjustment of the water heater gas control valve, refer to thewater heater installation instruction manual and the ratingplate attached to the water heater.

WARNINGWhen the system requires water at temperatureshigher than required for other uses, the hot watersystem may require that a means such as a mixingvalve be installed to temper the water at certain pointsof use.

WARNINGNever allow small children to use a hot water tap, or todraw their own bath water. Never leave a child orhandicapped person unattended in a bathtub or shower.

5. Vent Grundfos pump by loosening the screw in thecenter of the pump as shown below. Retighten thescrew as soon as water appears. Units equipped withTaco pumps need not have their pumps vented.

6. Energize the unit by switching on the line voltagesource and the thermostat. The fan and pump shouldstart simultaneously. The water coil should becomewarm, and after a few minutes of operation, anychurning noise in the pump should subside. It may benecessary to unwire the fan motor to listen for pumpoperation. Properly operating pumps are nearly silentin operation.

7. Repeat Step 5 to remove any remaining air fromGrundfos pump.

1. Turn the gas control knob to the “OFF” position.2. Turn the air handler thermostat off.3. Close the cold water inlet valve to the water heater.4. Open a nearby hot water faucet.5. Open the water heater drain valve.6. Perform cleaning procedure as necessary.

WARNINGHOTTER WATER CAN SCALD: Water heaters are intended toproduce hot water. Water heated to a temperature which willsatisfy space heating, clothes washing, dish washing, and othersanitizing needs can scald and permanently injure you uponcontact. Some people are more likely to be permanentlyinjured by hot water than others. These include the elderly,children, the infirm, or physically/mentally handicapped. Ifanyone using hot water in your home fits into one of thesegroups or if there is a local code or state law requiring acertain temperature water at the hot water tap, then you musttake special precautions. In addition to using the lowestpossible temperature setting that satisfies your hot waterneeds, a means such as a mixing valve, shall be used at the hotwater taps used by these people or at the water heater. Mixingvalves are available at plumbing supply or hardware stores.Follow manufacturers instructions for installation of thevalves. Before changing the factory setting of the thermostatread the “Temperature Regulation” section in this manual.

11


12

HEAT PUMP AIR HANDLER

Do not install the coil in the return ductwork of a heat pump.The coil must always be installed in the supplyductwork–downstream from the heat pump coil. Preheatingair to the heat pump coil not only causes a loss of efficiency,but may also damage the compressor.

The circulator is pre-plumbed to the coil [with control box(24VAC coil–115VAC contacts)] to control the circulation ofhot water. Consult wiring and piping diagrams shown for RFCSeries.

CONTROL ASSEMBLY

ISOLATIONVALVE

ISOLATION VALVE

COLD OUTLET

HOTINLET

PREFERRED INSTALLATION POSITIONS

PREFERRED ACCEPTABLE

VERTICAL AIRFLOW

NOTACCEPTABLE

HORIZONTALAIRFLOW

DIAGONAL POSITIONSARE ACCEPTABLE

Setting Equipment - RFC SeriesRFC1520, RFC2025, RFC2030

The coil may also be installed in the supply duct work.This, however, will not allow the coil to be operatedsimultaneously with the furnace. Care should be taken tomount the coil far enough from the discharge of theexisting furnace so that the coil does not impede air flow.Maintain at least 8″ between heat exchanger and coil.

The coil may be installed in supply or return ductwork.The return duct installation is preferred in the event thatsolar, gas or oil water-heated sources are used for primaryand or preheating to the existing furnace. When installingretrofit coils in the return, remember that the air over theblower motor will be warmed, where prior to theinstallation of the coil, the air was room temperature.

This can cause blower motors operating under 160°Fmaximum on return of system marginal conditions to cycleon their thermal protective devices. Be certain to relocatethe filter so that all air through the coil is filtered air.

Read the “Safety” and “Preparing for the NewInstallation” sections prior to installation of the HydronicAir Handling System before beginning the installation. Ifyou do not completely understand or have any questionscontact a qualified installer before proceeding.

The installation must comply not only with this manualbut all local and National codes. Installation should allow25″ of clearance in front of the access panel for service.Avoid refrigerant and condensate line routing that makesservice panel removal difficult.

CAUTIONThis hydronic air handler as all hydronic air handlers willeventually leak. Do not install without adequate drainageprovisions where water flow will cause damage.

Hydronic CoilPLEASE READ COMPLETELY BEFORE ATTEMPTING TOINSTALL THIS COIL.

The coil may be used with almost any gas, oil, or electricfurnace or with a heat pump, air conditioning blower, oras an “in line” duct-mounted heater to supply additionalor zoned winter comfort to hard to heat areas. CAREMUST BE TAKEN TO PROPERLY INSTALL THE COIL TOPREVENT DAMAGE TO EXISTING EQUIPMENT.(GAS/OIL/ELECTRIC FURNACE/AIR CONDITIONER ORAIR HANDLER.)

PUMP

13

GRUNDFOSPUMP

TACOPUMP

TO 24 V. CONTROLSOURCE

115 V. SUPPLY CIRCUITBY N.E.C.

WHITE

BLACK

RED

YELLOWBLACK

WHITE

4 x 4 JUNCTION BOXBLACK

Wiring for RFC Series

GROUNDBLACK

WHITE

Setting Equipment - RFC Series

DRAIN PAN

AIR HANDLER UNITCOLD OUTLET

HOT INLET

Refer to the typical installations on page 5, andinstallation notes on page 6 when connecting the waterheater to the air handler.

Water heaters used for space heating must be listed andlabeled as “suitable for (potable) water heating andspace heating”.

Water heaters used for space heating must also be usedfor domestic (potable) water heating.

Typical InstallationSpecifications subject to change without notice.Installation of this product must comply with prevailingbuilding, safety and N.E.C. codes and should be inaccordance with manufacturer’s instructions.



Before installing the air handler check blower wheel forfree rotation.

This unit can be used in upflow and down flow dischargepositions and also in horizontal discharge positions wherethe access panel is located at the top or bottom of theunit.

Horizontal discharge positions that cause the pump shaftto be vertical are not acceptable.

Maintain ample clearance outside of the access panel toallow for servicing. Clearance to combustible material is 0″to the sides and back. The discharge clearance is also 0″.

Suspend the unit using the mounting hardware included.The two 16″ angle brackets are to be secured to thesupport structure using the isolation grommets andeyelets. The eyelets will accept 1⁄4″ hardware such as lagbolts, threaded rod, etc. Do not overtighten the mountinghardware since this will reduce the noise isolation effectof the grommets. Please follow the assembly diagram asclosely as possible.

14

COLD OUTLET

HOT INLET

THERMOSTAT

AIR HANDLERUNIT

GROMMET

METAL EYELET

1⁄4″ FASTENER (rod, lag screw orbolt...field supplied)

Setting Equipment - HH2000 SeriesCAUTION

This hydronic air handler as all hydronic air handlers willeventually leak. Do not install without adequate drainageprovisions where water flow will cause damage.


COLDOUTLET

BLOWER MOTOR

TRANSFORMER

RELAYS

BLOWERASSEMBLY

HOT INLET

PUMP

ISOLATIONVALVES

HOUSING




15

HOUSING

RELAYS

TRANSFORMERPUMP

COLD OUTLETHOT INLET ISOLATION VALVES

BLOWERASSEMBLY

CAUTIONInstallation of the air handler must be accomplished insuch a manner that if the condensate drain connectionsshould plug or other causes create an overflow, the flowof (condensation) water will not cause damage to thearea adjoining the air handler of to lower floors of thestructure. When such locations can’t be avoided, asuitable drain pan should be installed under the airhandler. Such a pan should be no greater than 11⁄2″deep, have a minimum length and width of at least 2″greater than the air handler dimensions and should bepiped to an adequate drain. Under no circumstances isthe manufacturer to be held liable for any waterdamage in connection with this air handler.

Setting Equipment - VB SeriesVB2418, VB2618, VB3024



Before installing the air handler, check blower wheel forfree rotation.

These units are for use in upflow applications only. If theair handler is installed in an area subject to freezing,consideration of its placement needs to be made.


HOT INLET

DRAIN PAN

SECONDARYDRAIN

PRIMARYDRAIN

AIR HANDLERUNIT

COLDOUTLET

THERMOSTAT





16

TRANSFORMER

HOUSING

DRAIN PAN COIL

RELAYSPUMP

BLOWERASSEMBLY

SERVICE PANELS

SHEET METALSCREWS

DRAIN PAN

COIL

Setting Equipment - HB SeriesHB2418, HB2618, HB3024, HB2400, HB3000

With the drain pan screws removed, the coil/panassembly will slide toward the blower and can then bewithdrawn from the cabinet.

Fit the coil and drain pan together as shown below andinstall in the cabinet. The evaporator should be pushedfully into the return end of the unit before reinstalling thedrain pan screws. Allow 25″ of clearance in front of theaccess panel for service.

Also, avoid refrigerant and condensate line routing thatwill make removal of the blower/pump access paneldifficult.




These units are designed for horizontal air flow only. Ifthe air handler is installed in an area subject to freezing,consideration of its placement needs to be made.


As shipped, the unit is configured for left-hand dischargeor airflow. The unit may be converted to right-handdischarge using the following procedure.

Set the unit such that the service panels face upward.Remove both service panels and then remove the two#10 x 1⁄2″ sheet metal screws securing the drain pan to thecabinet.

Note: The HB2618, HB2418, and HB2012 evaporatorshave a support/shield attached. This support need not beremoved or repositioned for unit reversal.

ISOLATION VALVE

HOT INLET

17

Evaporator Detail Model HB3024

Evaporator Detail Models HB2618 and HB2418

LIQUID LINE

LIQUID LINE

AIR FLOW

AIR FLOW

SUCTION LINE

SUCTION LINE

LIQUID LINE

AIR FLOW

SUCTION LINELIQUID LINE

AIR FLOW

SUCTION LINE

LEFT HAND

RIGHT HAND

LEFT HAND

RIGHT HAND

CAUTIONInstallation of the air handler must be accomplished insuch a manner that if the condensate drain connectionsshould plug or other causes create an overflow, the flowof (condensation) water will not cause damage to thearea adjoining the air handler of to lower floors of thestructure. When such locations can’t be avoided, asuitable drain pan should be installed under the airhandler. Such a pan should be no greater than 11⁄2″deep, have a minimum length and width of at least 2″greater than the air handler dimensions and should bepiped to an adequate drain. Under no circumstances isthe manufacturer to be held liable for any waterdamage in connection with this air handler.

Setting Equipment - HB Series




SECONDARYDRAIN

PRIMARYDRAIN

COLD OUTLET

THERMOSTAT

HOT INLET

AIR HANDLERUNIT





There are two methods of framing in-the-wall mountunits. The first method described is easiest while thesecond lends itself to applications where the unitplacement is more critical. The units should be hung priorto the installation of sheet rock or other wall covering.

Method one involves using one stud in its originalplacement and moving the neighboring stud to providean opening the width as shown in the chart below. Then,a unit support “footer” should be installed between thevertical studs approximately 12″ to 16″ off the floor. Theunit footer should be level and substantial enough tosupport 150 pounds.

18

SEECHARTBELOW

2 x 4UNIT

SUPPORTFOOTER 12″-16″

Make sure that the 1″ outward flanges on the unit rest onthe vertical studs as flatly as possible, sheet rock (or otherwall covering) will finish on top of this flange and secure tothe exposed two by four studs on either side of the flanges.Once installed, the cabinet penetrations for low and linevoltage connections and for refrigerant line connectionsshould not be obstructed by framing members.

The second method, as shown below, involves placing aframing footer and header across two stud spaces with411⁄4″ vertical clearance between them. Vertical studsshould then be installed at 16″ on-center to provide anailer for sheet rock.

The illustration below shows the addition of framing studsbehind the unit’s vertical flanges providing a nailer forsheet rock. These can be left off if the sheet rock isscrewed to the flanges.

The unit will have to be set in from behind the wall (dueto the supply duct connection and pipe stubs) and canthen be secured top and bottom to the header and footer.

Next, the unit must be set in place and a header installedacross the top of the unit. The unit can be secured byscrewing downward through the bottom of the unit intothe footer, and upward into the header.

FRAMINGSTUDS

WIDTHMODEL MIN. MAX.W-2618 191⁄2″ 197⁄8″W-30-H 191⁄2″ 197⁄8″W-3024 191⁄2″ 197⁄8″W-4230 27″ 271⁄4″W-45-H 27″ 271⁄4″W-4535 27″ 271⁄4″

*Install onlyafter unit is set

in place.

2 x 4UNIT

SUPPORTFOOTER 12″-16″

UNITHEADER*

MUST BELEVEL AND

SECUREFOOTER

411⁄4″

HEADER

FOOTER

ADDITIONALFRAMING STUDS

FOOTER

Air FilterAir handlers are factory equipped with an air filter.

Removing the access panel will gain access to the filter. Itshould be checked periodically and replaced if necessary.The filter is a standard item that can be obtained athardware stores.


Setting Equipment - W SeriesW2618, W3024, W4230, W4535, W30H, W45H

19

COLDOUTLET

HOTINLET

AIR HANDLERUNIT

THERMOSTAT

Setting Equipment - W Series





20

Setting Equipment - S,M & L Heating Only ModelsSA30H, SA30HT, MA45H, MA45HT, LA55H

Read the “Safety” and “Preparing for the NewInstallation” sections prior to installation of the HydronicAir Handling System before beginning the installation. Ifyou do not completely understand or have any questions,contact a qualified installer before proceeding.




UP FLOW

SUPPLY

ELECTRICAL CONNECTIONS


WATER CONNECTIONS

PRIMARY DRAIN

DRAIN PAN

SECONDARYDRAIN

FILTERGRILL

RETURN

Refer to the typical installations on page 5 whenconnecting the air handler to a water heater withoutside connections for space heating.






WATERCONNECTIONS


PRIMARY DRAIN

DRAIN PAN


SECONDARYDRAIN

FILTERGRILL

RETURN

UP FLOW

21


The installation must comply not only with this manualbut all local and National codes. Installation shouldallow 25″ of clearance in front of the access panel forservice. Avoid refrigerant and condensate line routingthat makes service panel removal difficult.



Setting Equipment - S,M & L Models withEvaporator CoilSA3018, SA3024, MA4230, MA4536, MA4542, LA5048, LA5560





SHOWN STANDARD UPRIGHT POSITIONWITH FRONT PANELS REMOVED

(TOP DISCHARGE)

DOTTED LINES SHOWPOSITION OF DRAIN PAN:

FOR LEFT HANDDISCHARGE

FOR RIGHT HANDDISCHARGE

1. Lay the unit on it’s back, and remove lower panel.For LA Series–RH HorizontalInstall Splash Baffle. Slots in baffle fit tabs on back ofdrain pan. Install Evaporator Panel.

2. Remove coil securing bracket. Note: LA-Unit mayhave coil support bracket. Remove and save to installon left side.

COIL SECURING BRACKET

22

Horizontal Air Flow Conversion From Right Hand to Left Hand

Setting Equipment - S,M & L Models withEvaporator Coil (cont’d)

Note: Splash Baffle mandatory for LA Series Horizontal

COIL SUPPORTLA SERIES

WHEN USED

3. Being careful not to damage the coil, lift it from the cabinet, along with the drain pan.

4. Place the drain pan on the coil for left hand discharge,and return the coil with drain pan into the cabinet.Note: Drawing shows the drain pan installed for lefthand discharge.


FLIP THEDRAIN PAN

AS SHOWN RIGHT HAND DISCHARGE

5. Reinstall the coil securing bracket.


23

Horizontal Air Flow Conversion From Right Hand to Left Hand

Setting Equipment - S,M & L Models withEvaporator Coil (cont’d)

6. Replace the access panel. Note: Insulation must be cutaway and the rubber plugs moved depending on theposition (left or right discharge) of the drain pan.

24

FOURTH FRAMINGMEMBER

MOUNTINGANGLE

BRACKET

FRAMING MEMBERS ALTERNATEMOUNTING ANGLE

LOCATION

MOUNTINGANGLE

BRACKET

FRAMING MEMBERS

MOUNTINGANGLE

BRACKET

MOUNTINGANGLE

BRACKET

ALTERNATE MOUNTINGANGLE BRACKET LOCATION

Standard Return Air/Service PanelFor proper installation of the service and return airpanels, the finished drywall construction in the ceilingaround the air handler should come flush with the edgeof the cabinet. The service panel should then be attachedto the unit at the discharge end with four phillips headscrews in the holes provided. The “L” shaped hingebrackets should be slipped into the narrow slots in thereturn air panel and attached with two hex head screwsthrough the panel and into the brackets as shown inFigure 3. These hinge brackets will then slip through thecorresponding notches in the service panel allowing thelouvered return panel to pivot up against the cabinetwhere two phillips head screws will secure it to thecabinet.

Figure 1

Figure 2

INSTALL HINGES ASSHOWN

Figure 3

Setting Equipment - H SeriesH2418, H2824, H3230, H24H, H32H, H2418D, H2824D, H3230D


The installation must comply not only with this manualbut all local and National codes. Installation shouldallow 25″ of clearance in front of the access panel forservice. Avoid refrigerant and condensate line routingthat makes service panel removal difficult.


This piece of equipment is intended for overhead, furred-in installations. It has a return grille and filter to allowreturn air to enter the unit directly without additionalreturn ducting. When placing the unit, try to choose alocation that is central to the dwelling and cannot getisolated by shutting doors. Hallways are usually the bestlocation.

The unit is shipped with two mounting angles, in mostinstallations these will be screwed flush with the top ofthe unit across its 24″ sides. (See Figures 1 and 2) Theseflanges will then be used to secure the unit to the trussesor rafters. Use 1⁄4″ lag bolts, toggle bolts or threaded rodsfor this, #8 sheet metal screws may be insufficient. Oncethe unit is securely hung and the discharge ductinginstalled, it can be framed in. It is preferable, however, tohave the piping done prior to framing to insure easyaccess to the piping connections and to insure propergrade on the condensation drain.

The framing should be done with 2 x 4 studs laying flatso that they will not obstruct the holes for piping thedrains and hot water connections. The entire perimeter ofthe unit needs to be framed to provide a nailing surfaceand the nailing surface should be flush with the bottomflange of the unit. Sheet rock or other ceiling materialwill finish up to the edge of the unit. The grille andservice panels have 1⁄2″ of overhang at the front and backof the unit, and 3⁄4″ overhang on the sides of the unit.

In some cases, the framing may have to be done prior tohanging the unit. This is more awkward than the abovementioned framing method, but can be done. Due to thedischarge flange, it will not be possible to frame out a243⁄8″ x 353⁄8″ (or 453⁄8″) hole and then slide the unit intoplace. It is best to provide two nailers 353⁄8″ (or 453⁄8″)apart with a third stud spanning these at the point wherethe return end of the cabinet will rest (see Figure 2). Thefourth framing member can be attached only after theunit is in place. For this framing method, the mountingangles can be attached to the bottom edge of the unitand then screwed to the framing as shown in Figure 2.

CAUTIONThis hydronic air handler as all hydronic air handlerswill eventually leak. Do not install without adequatedrainage provisions where water flow will causedamage.

Setting Equipment - H Series

REFRIGERANT LINESTO CONDENSING

UNIT

AIR FLOWAIR HANDLER

UNIT SECONDARY PRIMARYCONDENSATE LINES(2″ TRAP REQUIRED)

THERMOSTAT

25

Discharge DuctingThis unit has its blower discharging directly into thesupply duct system resulting in high air velocities close tothe end of the unit. To insure efficient air flow, the supplyplenum attached to this unit should be a minimum ofthree feet long. Also, outlet runs should tap into this ductas far from the end of the unit as possible.

Refrigerant PipingHoles are provided in the side of the unit through whichfield installed refrigerant lines can be run. The evaporatorcoils are fitted with copper stubs to which the refrigerantline should be soldered. Use silver solder or other hightemperature brazing alloy intended for refrigeration work.The stubs are located close to the side of the cabinet so itis a good idea to protect the cabinet insulation from flamedamage with a small piece of sheet metal. Also, themanufacturer recommends that the refrigerant lines arefilled with dry nitrogen before soldering. This willminimize the formation of ash inside the lines that canclog the capillary strainer.

The evaporator in this unit is fitted with a drain pan forthe removal of condensation. This drain pan is providedwith a 3⁄4″ female NPT fitting. Using an elbow, fieldsupplied, the primary drain will be connected anddirected to either the left or right side opening of thecabinet. See Figure 5. A second stub is provided forconnection of a secondary or overflow drain. This 3⁄4″nipple can be piped to an area where any dischargedfrom it will be noticed, indicating a need for service.

When horizontal run exceeds 15 feet, a vent tee may benecessary to insure proper drainage.

The condensate drainage system should be tested bypouring water into the unit drain pan prior to operation ofthe unit.

Optional Service Panel forDucted ReturnThis solid panel is used when the return air is ducted intothe back of the unit. It is screwed to the bottom of the unitusing the screws provided.

Figure 4

NEOPRENE ELBOWSUPPLIED

DRAIN PAN

7⁄8″ O.D. TRAP

3⁄4″ IPS OVERFLOW STUB

Figure 5




Condensate DrainNOTE: Due to the critical elevations involved with theinstallations of drains for firred-in units, careful attentionneeds to be given that the drains are secure and thatthey have adequate grade. It is recommended that thedrainage of these units is tested prior to operation bypouring water into the drain pan. Once the ceiling isfinished, the drain line will be very inaccessible forservice.


26

Do’s and Don’tsFOR COMBINATION SPACE HEATING/DOMESTICPOTABLE WATER SYSTEMS

DO flush out all supply and return water lines betweenthe air handler and the water heater after installation andbefore startup to eliminate flux, metal chips, sand, orother particulate matter just as you would with anyplumbing system.

DO NOT operate in air conditioning mode when any ofthe following conditions exist:

• inside or outside temperature below 65˚F• low or restricted air flow• low refrigeration charge

DO NOT use with baseboard radiation (or other system)that has been served by non-potable water such as boilerwater or any other possible non-potable source.

DO NOT use the air handler in conjunction with newfinned tube baseboard radiation or convectors until youhave properly determined the capacity of those units withwater inlet temperatures of 140°F (or the temperaturewater you are going to use).

DO NOT use with piping that has been treated withchromates, boiler seal or other chemicals.

DO NOT add boiler treatment or any chemicals to anyair handler piping, when used in a potable water system.

DO NOT use with ferrous piping. The system should beinstalled only with new piping that is suitable for hot,potable water. Do not use with PVC piping.

DO NOT use any pumps, valves or fittings that are notcompletely compatible with hot potable water piping.

DO NOT use valves that may cause excessive restrictionto waterflow. Use full flow ball or gate valves only.

DO NOT use an air handler with any water heater nothaving a properly sized and installed Temperature-Pressure (T&P) Relief Valve. Some water heaters includefactory-installed valves. Others must be field-installed.Follow the instructions of the water heater manufacturerand local codes when installing the T&P valve.

DO NOT use any pumps, valves or fittings that are notcompletely compatible with hot potable water piping.

DO NOT use valves that may cause excessive restrictionto waterflow. Use full flow ball or gate valves only.

DO NOT use an air handler with any water heater nothaving a properly sized and installed Temperature-Pressure (T&P) Relief Valve. Some water heaters includefactory-installed valves. Others must be field-installed.Follow the instructions of the water heater manufacturerand local codes when installing the T&P valve.

DO NOT alter the water heater controls, dip tube, reliefvalve fitting, etc. The air handler does not require anymodification to a water heater. To do so may void themanufacturer’s warranty.

DO NOT turn the water heater thermostat all the way to“HIGH”. Properly applied air handlers are designed toprovide adequate heat with water heater temperatures setat 140°F or less. See water piping section on page 6.

DO NOT install air handler piping in any manner exceptas shown in the Instruction Manual.

SOME JURISDICTIONS may require a backflowpreventer in the incoming cold water line to the waterheater. In such cases, the Temperature-Pressure valve onthe water heater may weep or relieve due to expansion ofthe water when heated. Note that this would occur evenif an air handler system were not installed. If a system (airhandler/water heater) is installed in a closed and/or highpressure water system, contact the water supplier or localplumbing contractor on how to control this situation.

Troubleshooting

Troubleshooting (cont’d)Air Handler Service ChecklistIMPORTANT: Disconnect Power Source Before Servicing

CONDITION PROBABLE CAUSE POSSIBLE REMEDYSystem will not operate Water heater pilot out Relight pilot

Service switch turned off Turn on switchCircuit breaker off Reset circuit breakerFuse blown Replace bad fuseSystem off at water heater thermostat Check thermostatSystem off at air handler thermostat Check thermostatLoose wiring Check electrical wiringThermostat inoperative Replace

No heat Water heater pilot out Relight pilotPower not on Turn on powerWater heater not working Check water heaterPump air bound Follow System Start Up ProcedurePump seized Disassemble and check causeCheck valve stuck Remove obstructionThermostat inoperative ReplaceIncorrect thermostat Install correct thermostat. See instructionsPump inoperative Replace pumpPump relay inoperative Replace pump relayIsolation valves “OFF” Turn valves “ON”. See instructionsNo water in system Fill and vent system properlyWater not circulating Check piping for restrictions, air locks or flow directionPump backwards Reinstall properly or switch supply and return pipes

Insufficient heat Water heater thermostat set too low Turn control upWater heater input too low Install properly sized unitFilters clogged Replace filtersAir handler too small Install properly sized unitBlower speed too low Set higher speedHeat registers closed Open registersDepneumatic not installed properly Install properly. See instructionsWater heater dip tube not installed correctly Install properly. See water heater instructionsUninsulated water lines Insulate properly Wall thermostat inoperative Repair or replaceUnit panels off Reinstall panelsWater lines restricted Remove restrictionDucts loose or blocked Repair ductworkSediment build-up Clean water heater tank

Not enough domestic hot Water heater control set too low Raise setting. See water heater instructions. See warningswater Water heater not adjusted for rated BTU Set proper input. See water heater instructions

Water lines not insulated Insulate hot water pipingDraw exceeds recovery rate of water heater Reduce rate of draw until heater recoversDip tube broken or not installed properly See water heater instructions

Blower noisy Blower wheel scraping sides Re-align wheelBlower wheel not balanced Replace wheelBlower wheel loose Tighten set screwMotor shaft bent Replace motorBlower mounting loose Tighten screwsObjects in blower wheel Remove debris

Blower does not operate Inoperative blower relay Replace relayTransformer bad Replace transformerMotor inoperative Replace motorIncorrect or loose wires Correct wiringMotor overload Remove cause of overloadInoperative capacitor Replace

Consult Air Conditioning installation and service instructions if your system does not cool properly.27

28

FOR THE NAME AND ADDRESS OF THE COMPANY,REFER TO THE RATING PLATE ON THE UNIT

5 YEAR LIMITED WARRANTY ON HEATING COIL

The “Company” warrants the copper-tube aluminum finheating coil (heat exchanger) in this unit in case of aleak within five (5) years from the date of purchase or,in the absence of a Bill of Sale verifying said date, fromthe date indicated on the serial plate affixed to this unit;see EXCLUSIONS AND LIMITATIONS below. Incase of a defect, causing water leakage from this coil,or failure to conform to this warranty, the Companywill repair or replace this heating coil. No labor,installation, or freight (if any) charges are included inthis warranty. You must pay these costs.

5 YEAR LIMITED WARRANTY ON EVAPORATOR(COOLING) COIL (IF ANY)

The Company warrants the copper-tube, aluminum finevaporator (cooling) coil in this unit, if one is includedand provided that said coil was manufactured orfurnished by the Company, in case of a refrigerant leakwithin 5 years from date of purchase, or in the absenceof a Bill of Sale verifying said date, from the dateindicated on the serial plate affixed to the unit; seeEXCLUSIONS AND LIMITATIONS below. In case ofa defect in materials or factory workmanship causing arefrigerant leak from this coil or failure to conform tothis warranty, the Company will repair or replace thisevaporator coil. No labor, installation, or freight (ifany) charges are included in this warranty. You mustpay these costs.

LIMITED WARRANTY ON ALL OTHER PARTS

The Company warrants all other component parts ofthis unit to be free from defects in material andworkmanship for a period of one (1) year from the dateof purchase, or, in the absence of a Bill of Saleverifying said date, from the date indicated on the serialplate affixed to the unit; see EXCLUSIONS ANDLIMITATIONS below. In case of a defect, malfunctionor failure to conform to this warranty, the Companywill repair or replace, at its option, the parts. No labor,installation, or freight (if any) charges are included inthis warranty. You must pay these costs.

5 YEAR HEATING COIL-5 YEAR EVAPORATOR COIL-1 YEAR PARTS

PRODUCT WARRANTYSPACE HEATING AIR HANDLER, FAN COIL UNIT

OR HEATING COIL UNITEXCLUSIONS AND LIMITATIONS OF THESE LIMITED WARRANTIES

1. THE LIMITED WARRANTIES PROVIDEDHEREIN ARE IN LIEU OF ANY AND ALLWARRANTIES, EXPRESS OR IMPLIED,INCLUDING, BUT NOT LIMITED TO, IMPLIEWARRANTIES OF MERCHANTABILITY ANDFITNESS FOR A PARTICULAR PURPOSE;PROVIDED, HOWEVER, THAT IMPLIEDWARRANTIES ARE NOT DISCLAIMEDDURING THE ONE-YEAR PERIOD FROM DATEOF PURCHASE. SOME STATES DO NOTALLOW LIMITATIONS ON HOW LONG ANIMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

2. The Company shall have no liability hereunder,either direct or contingent, for incidental or consequential damages. Some states do not allowthe exclusion or limitation of incidental orconsequential damages, so the above limitation orexclusion may not apply to you.

3. This warranty gives you specific legal rights, andyou may also have other rights which vary fromstate to state.

4. These warranties shall be void and shall have noeffect:a. If the design or structure of the unit is, or is

attempted to be, modified or altered in any way,including, but not limited to, by attaching non-Company approved appliances or equipment.

b. If the unit is not properly installed in accordancewith the latest issue of (1) the National ElectricCode; (2) all local ordinances and regulationspertinent to this unit; and (3) the installation andinstruction manual provided with this unit.

c. If the water heating vessel in the hydronic loop isnot equipped with new pressure protectiveequipment required by local codes, but not lessthan a pressure relief valve certified by anationally recognized testing laboratory thatmaintains periodic inspection of production oflisted equipment or materials, as meeting therequirements for Relief Valves. This valve mustbe marked with a maximum set pressure not toexceed the marked hydrostatic working pressureof the tank.

d. If the air handler is not operated within the factorycalibrated limits.

e. If leaks in the Heating Coil or Evaporator Coil, ordefects in other parts, arise as the result of improperuse, negligence in operation, or accident, or inabilityof the unit to function because of repairs,adjustments, or replacements improperly madeoutside the Company’s factory, or because of fire,floods or lightning.

f. If leaks in the Heating Coil or Evaporator Coil ariseas a result of puncture by screws or other pointedobjects used during installation or servicing of theunit.

g. If the serial plate has been defaced or discarded andyou do not have a Bill of Sale to verify the purchase date.

h. If (1) installed in an area where leakage of the airhandler or connections would result in damage to thearea adjacent to the unit or beneath the unit, or (2)where such a location is unavoidable, a suitabledrain pan is not installed under the unit. When adrain pan must be used, the pan must be 11/2″ deepand must have a minimum size at least 2″ greater than the length and width of the unit on all sides,must conform to local code requirements (if any), and must be piped to an adequate drain usingminimum 3/4″ pipe with continuous slope away fromthe unit. The drain line should terminate in a locationwhere drainage water flowing would be visible to theeye.

i. If the air handler is used for any purpose other thanexpansion for hydronic space heating and coolingsystems.

j. If the air handler is used with any equipment or system that uses heavily chlorinated or otherwisenonpotable water.

k. If the unit water circuit or refrigerant circuit issubjected to pressures or temperatures greater thanthose maximum values specified on the unit ratingplate or in the installation instructions.

l. If leaks in the Heating Coil or Evaporator Coildevelop as a result of the unit being exposed to orhandling air from a highly corrosive atmosphericcondition.

m.If leaks in the Heating Coil or defects in other partsoccur as the result of the unit being operated withdesalinated (de-ionized) water.

n. If leaks in the tank or defects in other parts arise as aresult of sizing that does not comply with themanufacturer’s currently published sizing guides orsizing recommended by the manufacturer.

o. If this air handler or any part has been under water.

5. This warranty does not apply to air filters, to anypart attached to the unit that was not furnished bythe Company, to damage caused by freezing whenthe unit is installed in an unconditioned space, or todamage resulting from application of improperelectrical service or voltage.

6. This warranty does not apply to connecting tubinginstalled external to the unit, nor to the joints orconnections of said tubing to the unit.

7. Replacements and/or repairs furnished under thesewarranties do not carry a new warranty, only theunexpired portion of the original warranty.

8. The terms of this warranty may not be varied byany person, whether or not purporting to representor to act on behalf of the Company.

9. In order to obtain service under these warranties youmust promptly notify the installing contractor ordealer, giving the nature of the problem and themodel and serial number of the water heater. If forany reason the installer or dealer cannot be locatedor fails to provide satisfactory warranty service, youshould write the Company with the aboveinformation.

If after inspection, the installer or dealer, or theCompany, determines that repair or replacement isrequired under these warranties, you must pay thefreight charges involved, if any, including those toreturn the defective part(s) or unit.

This warranty does not apply to products installed inCalifornia.

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